Abstract:To meet the development of weapons and munitions toward insensitivity, low cost, and miniaturization, it is imperative to synergistically enhance the low-cost manufacturing, structural miniaturization, and low-energy firing capabilities of exploding foil initiators (EFIs). This paper reviews the material selection and structural optimization of key components of EFI , including tamper, bridge foil, flyer, barrel, and HNS-IV charge, and analyzes their impact mechanisms on device volume, firing energy, and manufacturing cost. Low-cost, miniaturized fabrication methods such as micro-electromechanical systems (MEMS) processes, low-temperature co-fired ceramic (LTCC) processes and printed circuit board (PCB) technology are introduced, along with compact EFI structures integrated with planar high-voltage switches. Furthermore, the effects of manufacturing deviations, assembly precision, and structural defects on initiation consistency are discussed, highlighting that high-precision integration can effectively reduce energy loss and improve initiation reliability. Finally, recent advances in cutting-edge technologies such as EFI overpressure chips, secondary flyer acceleration, polymer bonded explosives(PBX) micro-spheres based on HNS-IV micro- spheres are summarized, and the future development trends of EFIs toward precise design and intelligent manufacturing are outlined.
